The invention relates to a cutting assembly for use in thin and ultrathin web winding stations. It also relates to a method for cutting a web using this cutting assembly. According to the invention, the web (1) is cut by a blade (30) with a cutting edge transverse to the web transfer direction; the blade moves between a rearward position and a forward position; in the forward position, the cutting edge is substantially parallel to an axis of the roll (7) receiving the web, and the blade is substantially tangent to a surface of the roll. For cutting the web, the blade is moved from its rearward position to its forward position, so that its speed at the time it engages with said web is at least substantially equal to the speed of the web. This ensures a clean and clear cut of the web. At the same time, it ensures that the leading edge of the web is smoothly and evenly placed on the roll, without any creasing nor folding of the web.
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1. A cutting assembly, comprising an elongate housing; at least two guiding shafts having each a longitudinal axis transverse to the housing; a cutting blade mounted on at least one carriage; said at least one carriage being slidingly mounted on the guiding shafts and along the guiding shafts between a rearward position and a forward position for moving the cutting blade parallel to said axis of the guiding shafts; means for actuating and displacing said at least one carriage from the rearward position to the forward position; and means for holding said at least one carriage in its rearward position and for releasing said at least one carriage from its rearward position to the forward position.
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The invention relates in general to cutting knives and methods, and notably to the field of cutting knives and method for webs, and particularly plastic webs such as polyester, polyethylene, PET (polyethylene terephthalate) or PEN (polyethylene naphthalate) webs.
The manufacture of thin webs of plastic material such as polyester involves different operations to be performed on the webs, such as stretching of the webs, winding up of the webs on rolls, etc. It is also necessary to cut the webs, e.g. after a roll of a given size has been wound up. This causes several problems. The first problem is the actual cutting of the webs. The second problem is to deal with the leading edge and the trailing edge created through the cutting of the web. The third problem is to protect the core around which the web is supposed to be wound, since this core is supposed to be used several times. Ideally, a good cutting solution for webs and particularly plastic webs, should provide a clear and accurate cutting, and should allow the leading edge of the web after the web to be wound up easily, without stopping the web or slowing the speed of the web, and without any crease or fold in the web.
One type of solution for cutting such a web, while it is being wound up, it to use a knife moving transverse of the web winding direction or longitudinal axis of the web, that is along the axial direction of the rolls. Such a cutting apparatus is for instance described in U.S. Pat. No. 4,637,567, or in EP-A-0 606 662. The first of these documents discloses a knife formed of a flat blade having a flat surface, that moves transverse of the web longitudinal direction. The flat surface of the knife is brought into contact with the surface of the roll on which the web is to be wound; this contact avoids any crease or fold in the web as it is being cut. In addition, to ensure that the web fits on the new roll, the web may be moistened before it reaches the roll. EP-A-0 606 662 discloses a rotary cutting knife that travels along the axial direction of the roll.
For such knives moving along the axial direction of the rolls, the leading and trailing edges of the web are generally not perpendicular to the longitudinal axis of the web. Since the web to be cut travels along its winding direction, with a speed that can reach 450 m/min (7,5 m/s), the usual angle between the web edge and the longitudinal axis of the web may be quite high, even if the knife moves at a comparable speed. EP-A-0 606 662 exemplifies a knife moving at a speed of 600 m/min, and an angle of the leading edge of the web around 40°C. This causes loss of web at the beginning and end of each roll, or more generally, each time the web is cut. The amount of web lost may be up to several percents. It also makes the handling of the web more difficult for subsequent operations, due to the triangular shape of the end of the web, and thus the final conical shape of the wound up roll. Moreover, the winding up of the web on the winding roll is made more difficult since the triangle-shaped leading edge causes an asymmetrical profile on the core of the roll. Finally, such knives have to move at high speed, and should be accelerated and decelerated over short distances, so as to limit the bulkiness of the apparatus. This creates mechanical problems.
Another type of solution uses a knife with a cutting edge extending transverse of the web, that is reciprocated along the web winding direction to cut the web. U.S. Pat.No. 5,464,166 discloses a rotary cut-off knife assembly, having a cylindrical cut-off roll with a knife along one generating line of the roll; the knife may project out of the roll or be retracted. The operation of this device is the following: the cut-off roll is brought into contact with the web, with the knife retracted in the roll, and the knife is projected outside of the roll when the web is to be cut. In this document, it is suggested that the linear speed of the cut-off roll is higher than the travel speed of the web, and is typically 25% greater than the speed of the web. In order to bring the leading edge of the web to the core of the new roll, this document suggest cutting the web in the neighbourhood of the core roll, while generating an electrostatic charge on the core roll. For this purpose, it is suggested that the gap between the tip of the knife and the core roll be about 1.5 mm when the knife severs the web. The solution suggested in this document ensures that the web is cut transverse to the winding direction. However, accelerating the cut-off roll at a speed higher than the one of the web may cause a problem, especially for very thin webs wound at high speeds; indeed, before the web is severed, the cut-off roll is in contact with the web and rotates at a higher speed. Moreover, there is a wedge of air between the web and the core roll at the time the web is cut. The presence of air creates creases or folds and makes it difficult to ensure that the leading edge of the web is smoothly and evenly placed on the core. Finally, it would be advantageous to avoid using an electrostatic charge system.
U.S. Pat. No. 4,789,109 uses a blade powered by a compressed air box for cutting a web transverse its winding direction. In this document, it is suggested to incorporate the blade and its air box to a pusher device for rotating a completely wound web out of the winding device. The winding of the web must however be stopped for cutting the web and getting the wound roll out of the winding apparatus. The new core roll is provided with a glue stripe or with a 2-sided tape, and is lowered over the leading edge of the web. This device is highly disadvantageous in that it implies stopping web supply each time a new roll must be started.
Other types of cutting apparatuses have been suggested; U.S. Pat. No. 5,335,869 discloses a blade entering into a recess of a roll; U.S. Pat. No. 5,285,977 discloses a similar system where projections of one roll enter into recesses on another roll. These systems cannot cut the web directly in the neighbourhood of the core of a roll, and propose complicated solutions for bringing the leading edge of the web to the core of the roll where it should be wound. U.S. Pat. No. 3,047,248 discloses a reciprocating knife, mounted on oil pressure actuators, in a cloth winding circuit.
To summarise, none of the various solutions of the prior art provides a cutting apparatus that may be used for the cutting of thin and ultra thin webs in a winding station, while ensuring:
a clean cut transverse the winding direction of the web;
a smooth and even placing of the leading edge of the web on a new core roll, without any need to stop supplying the web to the station.
Accordingly, the purpose of the invention is to provide a solution that overcomes the problems of the prior art. According to the invention, there is provided a high speed knife moving along the web direction, tangent to the web and adjacent the core of the new roll, so as to ensure a clean and clear cut of the web, and at the same time, a smooth and even placing of the leading edge on the core roll.
The invention proposes a cutting assembly, comprising an elongate housing at least two guiding shafts transverse to the housing and slidingly supporting a blade through at least one carriage; said at least one carriage being movable between a rearward position and a forward position; actuating means for displacing said at least one carriage from the rearward position to the forward position; holding means for holding said at least one carriage in its rearward position and for releasing said at least one carriage from its rearward position to the forward position. Prefereably, the blade is a flexible blade.
The actuating means may be operated by a pressurised fluid, preferably pressurised air. They may comprise at least one cylinder with a piston connected to one carriage. The holding means advantageously comprise at least one trigger engaging a protruding section of said at least one carriage, and releasing means for disengaging said trigger from said protruding section. The releasing means may also be operated by a pressurised fluid, preferably pressurised air. They preferably comprise an inflatable tube capable of displacing said trigger when inflated.
The assembly may also comprise return means for bringing said at least one carriage from its forward position to its rearward position, or elastic means for receiving said at least one carriage when it reaches its forward position.
Prefereably, the cutting assembly further comprises a nose part mounted on said housing, near to said forward position. The nose part may be an elastic part. The assembly may also comprise a flexible plate mounted on the lower side of said housing, near to said forward position, and adapted to tangentially receive the blade when the blade is in its forward position.
The invention also relates to a web winding apparatus, comprising at least a roll and a cutting assembly located near a roll, said cutting assembly having a blade movable between a forward position and a backward position, wherein, in the forward position of the blade, a cutting edge of the blade is substantially parallel to an axis of the roll while the blade is substantially tangent to a surface of the roll.
Preferably, the apparatus further comprises a transfer roll, the roll is a winding roll, and the cutting edge of the blade in its forward position lies near the nip point between the winding roll and the transfer roll. The angle between the blade and a plane tangent to the roll at the contact line of the blade with the roll is preferably between 0°C and 10°C.
The invention finally relates to a process for cutting a thin web in a thin web winding station, comprising a roll receiving the web; a cutting assembly having a blade with a cutting edge, said blade being movable between a rearward position and a forward position where the cutting edge is substantially parallel to an axis of the roll and where the blade is substantially tangent to a surface of the roll, the process comprising the step of moving said blade from its rearward position so that its speed at the time it engages with said web is at least substantially equal to the speed of the web.
Preferably, the process comprises the step of further accelerating said blade after it engages with said web. The cutting assembly is advantageously at a location near the nip point between the transfer roll and the winding roll.
A cutting apparatus embodying the invention will now be described, by way of non-limiting example, with reference to the accompanying drawings, in which:
The cutting assembly comprises a housing 20 (represented here open on its lower side); a plurality of guiding shafts 22, mounted in the housing, and spaced along the length of the housing, each shaft having an longitudinal axis transverse the length of the housing; a carriage 24 slidingly mounted on the guiding shafts, and capable of moving along the guiding shafts 22 between a rearward position and a forward position, in which it abuts against elastic means 26 surrounding one end of the shafts 22; actuating means 28 mounted in the housing 20 and engaging the carriage 24 and being able to move the carriage 24 from its rearward position towards its forward position; a blade 30 mounted on the outer side of the carriage 24 facing the roll, and protruding from the carriage, in a direction substantially parallel to the axis of the guiding shafts 22. The cutting assembly further comprises a front elastic part or nose 32 mounted along the length of the housing, on a side of the housing nearer to the forward position of the carriage, that is nearer to one end of the guiding shafts 22. The nose 32 has the shape of a lip; fixed to the upper front edge of the housing and forming an angle of e.g. around 45°C with the axis guiding shaft; the nose extends substantially as low as the lower edge of the housing. A flexible plate 33 is located below the nose 32 and is adapted to receive the blade 30 during the last part of its displacement, said plate being so that the blade 30 will be moving tangent to said flexible plate 33 when the carriage 24 reaches its forward position.
The carriage 24 has a protruding section 34 engaging a trigger 36 of the housing; the trigger 36 may release the protruding section 34, due to operation of releasing means 38. In the embodiment of
In a preferred embodiment of the invention, the carriage 24 extends on the whole length of the cutting assembly, that is on the whole width of the film to be cut. The carriage provides the necessary stiffness to the blade, that may be a thin and flexible blade, as discussed below. Thus, the invention allows to limit the weight of the moving parts of the cutting assembly, this ensuring that the blade may reach a high speed with a high acceleration. In addition, the light weight of the moving parts lessens the mechanical constraints on the knife assembly.
The operation of the cutting assembly of
The trigger system of the cutting assembly of
The forward position of the blade and carriage is represented on FIG. 2. The carriage 24 abuts against the elastic means 26, when reaching the forward position. The blade, at that time, had passed beyond the flexible plate 33 and the cutting edge of the blade lies about underneath the end of the nose 32. Pressure in the cylinders is reset to zero from external means such as a two way valve, that are activated after the cutting operation, e.g. 1 second or so after the cutting operation. The pressure in the inflatable tube 40 may also be caused to decrease. The return means may then be operated to bring the carriage 24 back to its rearward position; when the carriage 24 is brought back the rearward position, the trigger engages again the protruding section of the carriage. The cutting assembly may then be operated again for another movement of the blade 30.
The cutting assembly according to the invention provides a reliable, fast and precise movement of the blade 30, with a speed that can be adjusted according to the pressure applied to the cylinders 42 of the operating means. The blade 30 may be of any shape appropriate for performing the cutting. Examples are doctor blade and blade with teeth. Preferably, the blade has a low weight, so that it may be accelerated easily and quickly over a short distance. It may also be flexible, this ensuring full tangential contact of the blade with the roll surface, in spite of small surface irregularities. The fact that the speed, of the knife may be higher than the one of the web to be cut ensures that even a serrated blade will not produce elongated strips of web, but a clean and clear cut.
The cutting method according to the invention is now explained. This method may advantageously be carried out using the cutting assembly described above in reference to
Preferably, the angle between the blade and the plane tangent to the roll at the contact line of the blade with the roll is between 0°C and 10°C. A value around 2°C, the blade being slightly directed toward the center of the roll, ensures a good cutting of the web, while still protecting the roll.
At the time the web is to be severed, the blade of the cutting assembly is released, and impinges on the web, tangent to the outside surface of the roll, at a speed higher than the speed of the web. This ensures, one the one hand, that the web is severed, with a clean and clear cut. On the other hand, this ensures that the leading edge of the web remains in contact with the roll 7, without any need for specific means such as electrostatic charging means, 2-sided tape or a strip of glue. Since the blade is tangent to the outside of the roll, there is no air trapped between the web and the roll at the time the web is cut. This avoids the problems of the prior art discussed above, and ensures a smooth and even placing of the leading edge on the roll. In addition, since the blade is tangent to the roll and first contacts the web. The roll is not damaged by the cutting of the web, and may be used again later.
The invention thus ensures the proper cutting of the web, and at the same time, the proper placing of the leading edge of the web on the roll. As compared to the prior art, it provides a simpler and more efficient solution.
The winding apparatus of
The process for operating the apparatus of the invention is as follows. At the starting point of the process, step -a-, the web is fed from the transfer roll 5 to the first winding roll 8, where it is wound; at that time, the transfer roll 5 may contact the winding roll. At step -b-, when the roll 8 has reached its desired diameter, the transfer roll 5 is retracted and the winding rolls 7 and 8 are rotated counter-clockwise, so that an empty roll 7 comes near to the transfer roll. The roll 5 is then brought into contact with the empty winding roll 7. At that time, the web is fed from the transfer roll 5 to the empty winding roll 7 and then to the winding roll S. This situation is represented on FIG. 4.
At step -c-, the cutting assembly is moved to its cutting position, where the blade of the cutting assembly is substantially transverse and tangent to the web and its underlying winding roll 7. This situation is represented on FIG. 5. In the cutting position, the cutting assembly is located near the nip point between rolls 5 and 7. The position of the cutting assembly in step -c- is also the one represented in
Step -d- is optional and consists in moving the cutting assembly slightly away from the first winding roll 7, e.g. a few mm, typically 1 mm or less. This may he useful to avoid any damage to the roll during the cutting of the web. The process then proceeds to step -e-.
At step -e-, the actuating means of the cutting assembly are pressurised. The pressure is chosen according to the speed of the web at the cutting point, so that the speed of the blade at the time it engages with the web is at least substantially equal to the speed of the web.
At step -f-, the releasing means are operated, so that the blade moves from its rearward position to its forward position. This is represented at
Thereafter, at step -g-, the cutting assembly is brought back to its retracted position; the pressure in the cutting assembly is reset to zero, and the return means bring the blade back to its rearward position, where the trigger engages the carriage. The second winding roll 8 may be then discharged, and a new empty core may be mounted; the cutting assembly is withdrawn to the retracted position of FIG. 4. The process is then ready to proceed again from the starting point discussed above.
The invention was described in reference to a preferred embodiment. Many variations are possible; for instance, the length of the blade can be adapted to the width of the web to be cut. The embodiment of
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Executed on | Assignor | Assignee | Conveyance | Frame | Reel | Doc |
Sep 03 2000 | PETITJEAN, GILLES | E I DU PONT DE NEMOURS AND COMPANY | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 011123 | /0067 | |
Sep 19 2000 | Du Pont Teijin Films UK, Ltd. | (assignment on the face of the patent) | / | |||
Oct 22 2003 | PETITJEAN, GILES | DUPONT TEIJIN FILMS U S LIMITED PARTNERSHIP | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 014358 | /0353 | |
Nov 19 2003 | E I DU PONT DE NEMOURS AND COMPANY | DUPONT TEIJIN FILMS U S LIMITED PARTNERSHIP | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 014358 | /0363 |
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